Deformation and energy absorption of additively manufactured functionally graded thickness thin-walled circular tubes under lateral crushing

Abstract Functionally graded thickness (FGT) is an innovative concept to create light-weight structures with better material distribution and promising energy absorption characteristics suitable for vehicle crashworthiness applications. Accordingly, this paper suggests circular tubes in-plane gradient along their perimeter assesses behaviour under lateral loading. Three different designs of were considered in which the locations maximum minimum thicknesses are varied. Selective laser melting method additive manufacturing was used manufacture tubes. Two bulk powders including titanium (Ti6Al4V) aluminium (AlSi10Mg) process. Quasi-static crush experiments conducted on melted investigate crushing behaviour. The FGT calculated compared against a uniform design. results revealed that best metrics offered by tube regions horizontal vertical directions while at angle 45° respect loading direction. aforementioned found absorb 79% greater per unit mass than its counterpart. Finally, aid numerical simulations surrogate modelling techniques, multi-objective optimisation parametric analysis tube. influences geometrical parameters responses structure explored optimal determined. reported provide valuable guidance design deformation.